Process for the preparation of non-combustible shaped articles

ABSTRACT

A non-combustible shaped article which is composed of the base material shaped of a mixture comprising a hydraulic inorganic composition consisting of a water-insoluble inorganic substance composed predominantly of silica and another inorganic substance composed predominantly of calcium oxide, and mineral fibers, under addition of water, and a surface material integrally bound on at least one surface of said base material, which is applied to said surface as an aqueous dispersion of a hydraulic inorganic composition consisting of a water-insoluble inorganic substance composed predominantly of silica and another inorganic substance composed predominantly of calcium oxide, or of the mixture of said hydraulic inorganic composition with at least one member of the group consisting of water-soluble silicate compound, zirconium compound and alkali metal hydroxide, and then hardened under heating as an integral structure, and a process for the preparation thereof.

Umteu mates Patent 1191 1111 3, Ueda et al. 1 Mar. 25, 1975 [54] PROCESS FOR THE PREPARATI ON OF 2,946,695 7/1960 Dietz et a1. 106/84 NONCOMBUSTIBLE SHAPED ARTICLES 3,285,757 11/1966 Cornely 106/84 1751 Harm-SM veda, Osaka; Naoyuki 1231333 511338 111 5361221131 :11: 152/1589 Suzuki, Nara; Masami Nagao, Takatsuki; Satoshi Shiroza, Ibaraki;

Primary Exammer-W11l1am D. Martm Hmsh; Hayashl Ukyo an of Japan Assistant Examiner-Sadie L. Childs [73] Assignee: Sekisui Kagaku Kogyo Kabushiki Attorney, Agent, or Firm-Wenderoth, Lind & Ponack Kaisha, Osaka, Japan [22] Filed: Apr. 12, 1973 [57] ABSTRACT [21] Appl. No.: 350,635 A non-combustible shaped article which is composed of the base material shaped of a mixture comprising a Related Apphcanon Data h draulic inor anic composition consisting of a water- [62] Division of Ser. No. 213,224, Dec. 28, 1971. mm substance composed pred0mi nantly of silica and anothe 'il g ggl mhstance com- [30] Foreign Application priority D posed predominantly of calcium oxide, and mineral Dec. 29. 1970 Japan ..45-124124 fi under addmo" 0f Water, and l ffi fifi 1 1n e g ra11 y bound on at least one surface of sa1d base 52 us. (:I.. 117/123 A, 106/94, 106/315, z g gf ff g gfif 5552:395

117/169A 264/133 P [51] In Cl C03c 17/22 C04b 41/24 cons1st1ng of a water-msoluble morgamc substance 58 Field of Search 117/123 A, 169; 264/333, gg ff fg gfi?gg lf gg iggf igi f g zg mg oxlde, or of the mlxture of sa1d hydrauhc morgamc [56] Refere'nces Cited composition with at least one member of the group consisting of water-soluble silicate compound, Zirco- UMTED STATES PATENTS nium compound and alkali metal hydroxide, and then 2.358.701 9/1944 Gardner 106/315 hardened under heating as an integral structure, and a Parry 1 process for the prepar tion thereofi 2.698.251 12/1954 Shea ct 211.... 106/120 2,946,158 7/1960 Seipt 117/123 A 11 Claims, No Drawings PROCESS FOR THE PREPARATION OF NON-COMBUSTIBLE SHAPED ARTICLES This is a division of application Ser. No. 2l3,224, filed on Dec. 28, 1971.

This invention relates to non-combustible shaped articles. More particularly, the invention relates to noncombustible shaped articles formed of integrally bound base material and surface decorative material of high strength and excellent waterproof property, said base material being made of a hydraulic composition consisting of water-insoluble inorganic substance chiefly of silica and another inorganic substance chiefly of calcium oxide, and mineral fibers.

Non-combustible shaped articles formed by addition of mineral fibers to cement, gypsum, etc. to improve the latters physical strength as well as non-combustible property are known. Conventionally the surface finish of such non-combustible shaped articles has been effected by physically adhering to the surfaces of such articles, decorative sheets or laminates, using adhesives. However, the operations for such practice are complex, and the products are subject to such deficiencies that the adhered surface sheets tend to peel off, and their surface hardness is reduced when the surface sheets contain organic materials.

Furthermore, combustible polymers, etc. are frequently employed as the materials of conventional decorative sheets, and therefore when heated, gasifyable components in the decorative sheets tend to discharge toxic gas or smoke. Thus the articles are quite inappropriate as construction materials.

The object of the present invention is to provide noncombustible shaped articles in which the base and surface decorative materials are integrally bound by chemical reaction so that the surface layer never peels off from the base, and which exhibit high surface hardness, and excellent waterproof property and heat resistance.

Another object of the invention is to provide a process for the preparation of such non-combustible shaped articles.

Still other objects and advantages of the invention will become apparent from the following specification and appended claims.

According to the invention, non-combustible shaped articles prepared by applying onto at least one surface of the base material which has been shaped of a mixture comprising a hydraulic inorganic composition consisting of water-insoluble inorganic substance predominantly of silica and another inorganic substance predominantly of calcium oxide; mineral fibers; and water; as the surface material an aqueous dispersion comprising a hydraulic inorganic composition consisting of a water-insoluble inorganic substance predominantly of silica and another inorganic substance predominantly of calcium oxide, or an aqueous dispersion comprising a mixture of such hydraulic inorganic composition with at least one member of the group consisting of watersoluble silicate compound, zirconium compound, and alkali metal hydroxide: and hardening the base and surface materials, are provided.

The hydraulic inorganic composition employed in the non-combustible shaped articles of the invention is (t a mixture of water-insoluble inorganic substance composed predominantly of silica and another inorganic sibstance composed predominantly of calcium oxide.

The composition is not hardenable simply by addition of water, that is, not hardenable at room temperature. The composition undergoes the hydration reaction only when it is added with water, and heated to at low- 5 est 5 QQ, under the steam pressure, preferably to 80 to -0011. under the steam pressure, and imrdened. In t is point the composition is clearly distinguishable from conventional hydraulic inorganic materials such as cement,-gypsum, mortar, concrete, etc., which are l hardenable at normal temperature and pressure.

The water-insoluble inorganic substance composed predominantly of silica" refers to the inorganic substance containing SiO in free state (i.e., SiO: is not bound with other atoms or atomic groups as in sodium 15 silicate, Na O.SiO-;) and allowably other minor quantities of impurities, such as alumina, Fe- O NaO, etc., specific examples of which including silex, siliceous sand, aplite, pottery stone, silicate terra able, paigeite, diatomaceous earth, fly ash, and germ;-

Also the inorganic substance composed predominantly of calcium oxide" refers to the inorganic matter which can provide calcium oxide to cause the formation ofa crystal system, SiO.CaO.H O, upon hydration reaction with the silica inmter-insoluble inorganic substance, specific examples of which including cement, slaked lime, quick lime, calcium carbonate and gypsum.

The water-insoluble inorganic substance composed predominantly of silica and the inorganic substance composed predominantly of calcium oxide are present in the hydraulic inorganic composition preferably in finely divided form, so as to improve the homogeneity of the composition. The preferred particle size is not greater than 325 mesh (Tyler), particularly approximately 5 microns.

Suitable blend ratio of the two organic substances in the hydraulic composition for the base material is such that the molar ratio of the calcium oxide contained in the second inorganic substance to the silica in the water-insoluble, inorganic substance should range from 0.5 to 2.0, preferably 0.6 to 1.2. Also for the surface material, the suitable blend ratio is such that the similar molar ratio should range from 0.8 to 4.0, preferably 1.2 to 3.0. Furthermore. the optimum results can be obtained when the molar ratio is higher in the surface material than that in the base material.

However, when the molar ratio of calcium oxide to silica is made greater than 4.0, the amount of calcium oxide remaining unreacted becomes conspicuous, and consequently the resulting non-combustible shaped articles are apt to form calcium hydroxide as reacted with water, reducing the hardness of the surface material. Therefore, such high molar ratio should be avoided.

The mineraLfibers to be employed concurrently with the hydraulic composition for the base material are the inorganic fibrous materials exhibiting no hydraulic property themselves, such as, for, example, chrysotile asbestos (3MgO.SiO .2H O), amosite asbestos [(FeMg)fiSi,,O- e(OH)- l, crocidolite asbestos INa- Fe,,. Si,,O2-.-(OH l. amphibole asbestos [Ca. Mg,-,Si,,O- (OHlL-l. tremolite asbestos lCa- Mg Si o -itOHl l, ac tinolite asbestos [Ca(MgFe);,(SiO- ),H O], rock wool. glass fibers, and slug wool. The mineral fibers particufi larly play a role of reinforcing the non-combustible shaped articles. Preferably. therefore, the mineral fibers have a length of 3 to 30 mm, particularly 5 to mm. Mineral fibers shorter than 3 mm do not serve for the reinforcing purposes expected of their fibrous form. if the mineral fibers are longer than 30 mm, they tend to get entangled with each other and become hardly uniformly dispersible in the hydraulic composition.

In the base material, suitable amount of the mineral fibers to be added to the hydraulic composition ranges from to 200 parts, particularly to 100 parts, per 100 parts of the hydraulic composition, the parts being by weight.

The base material may contain, in addition to the mineral fibers, organic fibers to improve the reinforcing effect by the fibrous materials. Examples of organic fibers useful for this purpose include: polypropylene fibers, polyethylene fibers, polyvinyl alcohol fibers, polyamide fibers, acrylic fibers, polydinitrile fibers, polyester fibers, polyvinyl chloride fibers, polyvinylidene chloride fibers, polynosic fibers, acetate fibers, urea fibers, artificial silk, rayon staple fibers, cotton, silk, flax, and animal fibers.

The amount of such organic fibers, however, should not exceed 20 parts per lOO parts of the hydraulic composition for base material, particularly suitable range being 1 to 10 parts, the parts being by weight. When it exceeds 20 parts, the non-combustible property of the shaped articles deteriorates due to the combustibility of organic fibers.

One of the unique features of the shaped articles of this invention resides in that the base comprising a hydraulic composition and mineral fibers, and; optionally, organic fibers, is chemically bound with surface material to provide an integral structure.

The structure material according to the invention is formed of a hydraulic composition consisting of a water-insoluble, inorganic substance composed predominantly of silica and another inorganic substance composed predominantly of calcium oxide; or of the mixture of such hydraulic composition with at least one member of the group consisting of water-soluble silicate compound, zirconium compound, and alkali metal hydroxide.

The hydraulic inorganic composition for the surface material may be similar to that for the base material. As already mentioned, the molar ratio of calcium oxide in the second inorganic substance to the silica in the water-insoluble inorganic substance should preferably be higher in the hydraulic composition for surface material.

The surface material in accordance with the invention may be formed of the hydraulic composition alone, or of the mixture of the hydraulic composition with at least one member of the group consisting of watersoluble silicate compound, zirconium compound, and alkali metal hydroxide.

The silicate compound is distinguishable from the inorganic substance composed predominantly of silica in that the former is water-soluble. As the useful watersoluble silicate compound, for example, the following may be named: sodium ortho-silicate, sodium sesquisilicate, sodium disilicate, potassium meta-silicate, potassium disilicate, and potassium tetrasililcate. Water glass can be used as one of such silicate compounds.

Also useful zirconium compounds are those which can provide zirconium oxide (ZrO) under the hardening conditions, such as zirconium oxide, zirconium silicate. zirconium carbonate, and zirconium. hydroxide, zirconium oxide being particularly preferred.

As the alkali metal hydroxide, potassium hydroxide, sodium hydroxide, lithium hydroxide, and the like can be used, sodium hydroxide being particularly preferred. Because those alkali metal hydroxides possess the action to accelerate the hardening speed of the hydraulic inorganic composition, they may be contained also in the base material, for promoting its hardening.

in the surface material, those silicate compound zirconium compound, and alkali metal hydroxide may be used singly, or more than one of them may be concurrently used. The suitable amount to be added is not more than 20 parts, particularly 0.] to 15 parts, per I00 parts of the hydraulic composition for the surface material, the parts being by weight. lfthey are added in the amount exceeding 20 parts, satisfactory integration of the surface material and base becomes difficult to be achieved during their hardening.

According to another embodiment provided by this invention, the surface material may contain, besides the hydraulic inorganic composition, water-soluble silicate compound, zirconium compound and/or alkali metal hydroxide; a resinous additive, to smooth the surfaces of the shaped articles and further reduce the water-absorbing property and hygroscopicity of the surface material.

The resinous additive" usable in the surface material according to the invention is the synthetic resin of the molecular weight ranging from 50,000 to 500,000, including non-elastic, thermoplastic synthetic resins, thermoplastic rubbery high molecular weight compounds and thermosetting synthetic resins.

The non-elastic, thermoplastic synthetic resin. thermoplastic, rubbery high molecular weight compound, and thermosetting synthetic resin, can be used singly, or as mixture of more than one of such substances.

Examples of the non-elastic thermoplastic synthetic resins include olefin resins such as polyethylene resin, polypropylene resin, copolymers of ethylene and other monomers copolymerizable therewith; styrene resins such as polystyrene resin, and copolymers of styrene with other monomers copolymerizable therewith; vinyl resins such as vinyl chloride resin and vinyl acetate resin; polyamide resins; polyacrylonitrile resin; polyacrylate resin; saturated polyester resins; cellulose acetate resins; and polyethylene oxide.

Examples of the thermoplastic rubbery high molecular weight compound that can be used in the invention include natural rubber, polyisoprene rubber, polybutadiene rubber, polypropylene oxide, polychloroprene rubber, polyisobutylene, rubbery isobutylene/isoprene copolymer, rubbery ethylene/propylene copolymer, rubbery styrene/butadiene copolymer. rubbery chlorosulfonated polyethylene, acrylic rubber, rubbery ethylene/vinyl acetate copolymer.

As the thermosetting resin, there can be USEdMJ- rated polvester IESlSlS, epoxy resins, urea resins, melamine resins, and phenolic resins.

Such resinous additive can be contained in the hydraulic inorganic composition for the surface material. in an amount ranging l to l0 parts, preferably 2 to 5 parts, per parts of the hydraulic composition, the parts being by weight.

When the amount of resinous additive in less than one part by weight, the surface unevenness of the shaped articles cannot be completely mended upon applying the surface material onto the base and hardening the same, and although the surface hardness can be somewhat improved, hygroscopicity and waterabsorbing property cannot be appreciably reduced. On the other hand, if it is greater than parts by weight, the articles water-absorbing property and hygroscopicity are reduced, but the surface hardness is objectionably reduced. Also because the organic resin component, in the surface material is so increased, the articles non-combustible property is deteriorated.

Accordingly to still another embodiment provided by the invention, thesurface material may contain inorganic pigments which are conventionally used with construction material. As such inorganic pigments, red iron oxide, chrome yellow, prussian blue, ultramarine, iron black, molybdenum red, zinc chromate, etc. may be named. They may be used singly or as mixture, in an amount not more than 20 parts, preferably from 3 to 10 parts, per 100 parts of the hyraulic composition for surface material, the parts being by weight.

It is also permissible, according to the invention, to form an organic or inorganic paint layer on the surfaces of shaped articles, instead of adding such inorganic paint to the surface material. As the organic paints useful for this purpose, for example, acrylic paint, styrene/acrylonitrile paint, vinyl acetate paint, etc. may be named, and as the inorganic paint, water glass type paint can be conveniently used.

Accordingly to this invention, there is also provided a process for the preparation of non-combustible shaped articles, which comprises the steps of:

1. adding to a hydraulic inorganic composition consisting of a water-insoluble inorganic substance composed predominantly of silica and another inorganic substance composed predominantly of calcium oxide: mineral fibers and water, and optionally, organic fibers, and thoroughly mixing the components,

2. shaping the mixture,

3. separately preparing an aqueous dispersion by dispersing in water, a hydraulic composition consisting of a water-soluble inorganic substance composed predominantly of silica, and another inorganic substance composed predominantly of calcium oxide, or a mixture of such hydraulic composition with at least a member of the group consisting of water-soluble silicate compound, zirconium compound and alkali metal hydroxide, and optionally, resinous additive and/or inorganic pigment,

4. applying said aqueous dispersion onto at least one surface of the shaped base as obtained in the step 2 )1 5. removing water content of the base applied with the aqueous dispersion under a pressure ranging from 50 to 500 kglcm 6. converting the above structure to semi-hardened shaped article by the primary aging at 60 90C. and atmospheric pressure, for 5 to 10 hours, and

7. subjecting the semi-hardened shaped article to the secondary aging at 150 2l0C. under a steam pressure ranging from 5 to 20 atmospheres, for 5 20 hours.

In the preparation of non-combustible shaped articles according to the invention, first mineral fibers, and optionally organic fibers, are added to the powdery hydraulic inorganic composition, and the mixture is thrown into a mixer, together with water, to be thoroughly mixed. The suitable amount of water in this case should be at least sufficient to complete the hydration reaction of the silica with calcium oxide in the hydraulic composition, i.e., 5 parts by weight per parts by weight of the hydraulic composition. However, for the maximum possible intimate mixing of the hydraulic inorganic composition with the fibrous component, preferably the water is used in large excess to allow thorough dispersing of the components therein, and thereafter the dispersion is filtered by suitable means to be removed of surplus water. Thus formed composition of the viscosity suitable for shaping is shaped with a suitable apparatus such as extruder, or passed through a web-forming machine, and shaped into optional form such as rod, sheet, plate, pipe, corrugated sheet, etc.

Thus shaped base material may be semi-hardened under heating at 50 l00C., but it is more advantageous to apply the surface material onto said base material as it is, and thereafter hardening the whole structure under heating.

The aqueous dispersion to be applied onto the base material as the surface material can be prepared by dispersing in water the afore-described hydraulic inorganic composition alone, or a mixture of such hydraulic composition with at least one member of the group consisting of water-soluble silicate compound, zirconium compound and alkali metal hydroxide, and furthermore, optionally resinous additive and/or inorganic pigment, and thoroughly stirring and mixing the system to impart thereto the viscosity suitable for the application onto the base surface or surfaces, preferably 5 50 poises, inter alia, l0 30 poises.

For the preparation of such aqeuous dispersion with the specified viscosity, if the hydraulic inorganic composition alone is to be used, 10 200 parts, preferably 80 l50 parts, of the composition is used per I00 parts of water. Also when a mixture of the hydraulic composition with water-soluble silicate compound, zirconium compound, and/or alkali metal hydroxide is used, 10 70 parts, preferably 20 50 parts, of the mixture is dispersed in 100 parts of water. lf resinous additive and inorganic pigment are to be added, the total of the resinous additive or additives should range 0.1 20 parts, preferably l l5 parts, and the inorganic pigment, 0.1 40 parts, preferably 0.2 10 parts, each per 100 parts of water, the parts being by weight.

Furthermore, alumina or the like may be advantageously added, as the hardening accelerator, to the hydraulic inorganic composition, to promote the hydration of base and surface materials and accelerate their hardening. The suitable amount of addition for this purpose is not more than 5 parts by weight per 100 parts by weight of the hydraulic inorganic composition.

Thus obtained aqueous dispersion is applied onto at least one surface of the base material shaped as already described by any of the conventionally employed means, such as spray coating. brush coating etc. The thickness of the surface layer to be applied should be sufficient to supplement the depressions on said surface to make it even, i.e., 0.l 5.0 mm, preferably 0.2 3.0 mm. When still improved surface smoothness and luster are desired, the coated surface may be contacted with a sheet of smooth surface such as of stainless steel, iron or plastics, and pressed as it is under a pressure of 50 500 kg/cm to be removed of the water content.

The shaped structure formed of the combination of base material and surface material is then heated to be hardened. The hardening can be effected by a single stage heating at 50 200C., under a pressure of l 20 atmosphere. More advantageously, however, the hardening is performed by a two-stage process as follows:

To wit, the structure is first aged under atmospheric pressure in steam of 60 90C., preferably 80C., for 5 to l hours. By this primary aging, the structure is converted to a semi-hardened shaped structure, which then is placed in a frame, and subjected to the secondary aging at 150 2l0C., preferably 180C., under a steam pressure of to 20 atmospheres. preferably 18 atmospheres, for 5 to 20 hours, preferably in a high temperature and high pressure reactor (autoclave). Whereupon the structure is completely hardened.

When thus obtained shaped article is to be further applied with a paint layer, suitable organic or inorganic paint or paints are applied onto the surface of the surface material. and dried.

Thus obtained non-combustible shaped articles according to the process of this invention never causes peeling of the surface material off from the base, because the water-insoluble, inorganic substance composed predominantly of silica and the inorganic substance composed predominantly of calcium oxide, in the base material, and the similar inorganic substances, as well as the optionally present water-soluble silicate compound, zirconium compound, and/or alkali metal hydroxide, in the surface material, chemically react at the interface of the base and surface materials to form a crystal system and be strongly integrated. The articles also have smooth, decorative surfaces of extremely high degree of hardness.

The non-combustible shaped articles furthermore exhibit excellent waterproof property differently from conventionally employed construction materials such as mortar, concrete, and gypsum board, because of the coating of specified surface material, and can sufficiently with stand high temperature and heating.

Upon observation of the non-combustible shaped ar-.

ticles provided by this invention by means of X-ray diffraction and differential thermal analysis, it is confirmed that the base and surfaces materials have reacted, forming tobermolite type crystal system and whereby strongly integrating said materials. The absence of peeling-off phenomenon of the surface material from the base in the articles of this invention is presumably due to the above-confirmed feature. Also the hydraulic, inorganic composition constituting the surface material becomes tobermolite (Ca (Si,,O,,,H H O) type crystal system, and a part of which is converted to wollastonite or xonotlite to provide a structure withstandable to heating at as high as 600 l,00OC. Particularly when the molar ratio of calcium oxide to silica in the hydraulic inorganic composition forming the surface material ranges from 0.8 to 4.0, crystals of I-C S hydrate (Ca,,(Si. ,O1l(SiO2)(OH) and Hillebrandite (Ca(SiO )(OH are formed, and the articles are confirmed to have extremely high surface hardness and excellent heat resistance.

It is also confirmed that, when crystal as identified above are formed in the surface material, such calcium silicate compounds as crystalline tobermolite (Ca Si,,O,,,H- ),.H -O). and tobermolite undergoing crystallization (Ca ,;(Si,,O ,,H ,),,.H O) are formed in the base material.

Furthermore, when the water-soluble silicate compound, zirconium compound, and/or alkali metal hydroxide is used concurrently in the surface material, the hydraulic inorganic composition in said material reacts with such compound or compounds, to form fine crystals of the compound of the composition MmO.Si- O CaO.H O (M being an alkali metal when m is 2, or zirconium when m equals 1). Concurrent presence of such crystals with the already described crystal systems in the surface material notably improves the abrasion resistance of the article, and also markedly reduces the water-absorbing property and hygroscopicity of the surface material. Likewise, the presence of specified resinous additive in the surface material is confirmed to serve to appreciably reduce the water-absorbing property and hygroscopicity of the non-combustible, shaped articles of this invention.

According to the process of this invention, the shaped articles are formed simply by applying the surface material onto the base and heat-hardening them into an integral structure. Thus the preparation procedures are very much shortened, compared with the conventional practice to adhere the surface sheet to the base. Also because both the base and surface materials invariably contain the hydraulic inorganic composition consisting of the water-insoluble, inorganic substance composed predominantly of silica and another inorganic substance composed predominantly of calcium oxide, no surface cracking or peeling-off caused by the difference in thermal shrinkage of the materials takes place.

The non-combustible shaped articles obtained according to this invention can be given various shapes such as of flat sheet, curved plate, etc., and can be very conveniently used for wall, floor, ceiling, etc. and other various utilities where non-combustibility is required.

Hereinafter the invention will be explained with reference to working examples, in which parts are by weight, unless otherwise specified.

The non-combustible shaped articles obtained in the following Examples are measured of their physical properties by the tests specified below:

l. Surface hardness test:

115 B-7724 (measured with Brinnels hardness tester) 2. Pencil hardness test:

.llS K-540l (measured with a pencil scratch tester for coated film) 3. Weather-proof property test:

The condition of each sample after 1,000 hours exposure to open field in a weather-ometer (Violet Carbon Arc Weather Meter, Model WE-2, open type, product of Toyo Rika Kogyo K.K.) was observed with naked eye. The sample showing no surface hardness change, discoloration, efflorescence, and color irregularity was evaluated the highest.

4. Friction-pull test:

The square sample of 1 cm X 1 cm was divided into equal square parts as incised with a knife, and onto which an adhesive tape was intimately adhered. Then the tape was abruptly peeled off, and the amount of the surface material of the sample peeled off together with the tape was determined. When no square came off with the tape, the peeling was zero percent. and when all 100 squares came off, l007r.

5. Non-combustibility test:

The sample having a size of 22 X 22 cm was burned for 3 minutes, with a city gas burner in which air was fed at a rate of L liters/min. Thereafter, it was additionally burned with an electric heater with nichrome wire having a capacity of 1.5 KW/hr. for 17 minutes. The fuming. flaming and after-flaming was observed, and

The above non-combustible, molding composition was thoroughly kneaded with 8680 parts of water in a mixer, and thereafter either passed through the filtering machine to be removed of excessive water. or shaped the non-combustibility was determined from an overall 5 into a sheet with a wet machine. to be used as the base consideration of the results of the observation. material.

When no fuming, flaming, generation of toxic gas, 5 f I l and surface cracking occurred during the test, the samur mdtena ple was graded excellent.

Bmlmg test: l0 Silex (chemical composition: The sample of 50 mm X 50 mm in size was boiled in Si0 99. t 13kg 0.446;. F22 (MW/i m P ,1 lgnlllOll 0551 .;l lll'lS boil ng water for 4 hours. and (ll'lLd m an dryer of Slukcdlime (pumy: 9m) 2m) I05 C. for It) hours. Then the sample was tested of its c n s r mol m, performance. and its surface hardness. cfflorescence, i' 2 v I lnorganlc p|gment (cadmium yellow) and surface conditions were examined.

7. Abrasion resistance test: .llS K-o902-l963. The above composition was stirred with 300 parts of The sample of 100 mm X I00 mm in size was abraded water in a high speed agitator. and then was filtered to with the grinding paper (AA-l80) applied on the sur- 3 be removed of the solid component of large particle face of abrading wheel H-l 8 (that normally employed ZeS BX fie ing 325 meshfor abrasion of hard materials) mounted on a Taber Then the above Sheet-formed base material was P abrasion tester. under a load of 500 g, at the rotation In a frame of 9H) X L X 6 mm n ze. and HIO rate of the turn table 70 rpm, at ilC. and 651571 which the Surface material was Coated with a p y to R.H. The abrasion was repeated I00 times in each test a thickness 9 c h Coated Surface was run and the average abrasion value was calcu|ate contacted with a lusterous stainless steel sheet, and Alka|i resistance test: through which pressed under a pressure of 200 kg/cm Onto the sampie Surface 05 cc of 5% aqueous NaOH Thus shaped sh eet str ucture was sub ected to the priwas dropped, and 5 hours thereafter the samples surmar) agmg m 80 90 steam for 10 hours and 3" face conditions were examined. The sample showing no memo the Secondary agmg m autoclave at 180 discoloration and elution received high evaluation. and 8 atmospheres for 10 hours to be compleiely Heat Stabimy test. hardened. whereupon the base and surface materials The sample was heated for 30 minutes each at the were f mtegrated' varied temperatures as 200C 400C 500C and The article was thoroughly dried and sub ected to the 600C. in an electric oven of 250 X 250 X 500 mm in 15 Physlcal P y Whh excellent results size. After each heating the flcxural strength of the low: sample was measured. The sample which showed no flexural strength deterioration received high evalua- S f hardness; 40 tion. Pencil hardness: H

40 Weather-proof property: Excellent Peeling: 0% EXAMPLE Non-comhustihility: Excellent Base material EXAMPLES 2-4 223 833 fmgz gzg F501 00 4% 45 Example 1 was repeated except that the composiignigkm ms; 3 0, parts tlons for base material and surface material were varied Slaked imetpur tyr 7 I00 as shown in Table l below. Thus the non-combustible dfilgggf g3222;21 23 04 shaped articles having the properties also as shown in Asbestos fiber (5 mm in length) Table l was obtained.

Table 1 Example Example Example Composition No. 1 No. 2 No. 3

Base material Silex"" I00 parts l00 parts I00 parts Slaked lime" I00 100 I00 C aO/SiO mol ratio 0.8 0.8 0.8 M203 (hardening accelerator) 0.4 parts 2parts 2 parts Asbestos fiber (5 mm) ll0 I00 I00 Water 8680 24l6 24l6 Surface material Silex"" I00 lOO Diatomaceous earth" I00 Slaked lime"" 200 l00 l00 CaO/SiO mol ratio 1.6 0.8 1.2 M 0, (hardening accelerator) 2 2 Inorganic pigment cadmium yellow 3 2 red iron oxide 5 Water 300 200 200 Table l-Continued Example Example Example Composition No. l Nov 2 No. 3

Property test results Surface hardness 35 40 63 72 55 60 Pencil hardness 9H 9H 5H Weather-proof property Excellent Excellent Excellent 1.000 hours exposure) Pelling '71 0% 07: Non-combustibility Excellent Excellent Excellent ""Chemical composition of silex:

SiO-, 99.4%. M 0 0.4471. Fe O 0.0471 ignition loss: 0.22% Purity of slaked lime: 9871 "Chemical composition of diatomaceous earth:

SiO-, 78.56% M 0 l3.2l'7r, Fe o 4.l I'Z (:10 1.51%. MgO L257! H O 2-3 '7: ignition loss: l.l 1'71 EXAMPLE The above experiment was repeated except that the Base material amount of water glass added to the surface material 20 was varied in each run, as 3. 5. l0, and 20 parts. The results of measuring the water-absorbing property of Silex (chemical composition: the products in the similar manner were, respectively, 5' 520110-047 hours when 3 parts of water glass was used, and ignition loss: 0.22% 33 Parts 5mm lime (pum). 1 47 hours tn all of the other runs. Thus the water- AI 0 (CuO/SiOQmoI ratio =0.7) l absorption decreased with the increase in water glass i g fiber (5 mm) 50 ii content of the product. other properties remaining sub- Surface material Silex (chemical cont osition:

SK), 9 .406. Al- 0.44% H10 0.04'7:

ignition loss: 0.22% 50 parts Slaked lime (purity: 98%) 50 ((aO/SiO; mol ratio 0.8) Water glass (SiO INa O mol ratio 3.2) l A1 0 (hardening accelerator) l The above composition was homogeneously dispersed in l00 parts of water. stirred with a high speed agitator. and then filtered to be removed of the solid 45 component of large particle sizes exceeding 325 mesh.

The aforementioned sheet-formed base material was fit in a frame of H0 X 1.820 X 6 mm in size. and onto which the surface material was coated with a sprayer. to a thickness of 0.5 1.0 mm. On the coated surface then a lusterous stainless steel was placed. and through which the structure was shaped under a pressure of 200 kglcm Thus formed sheet was subjected to the primary aging in 80-90C. steam for 10 hours, and then to secondary aging in an autoclave of 180C, under a pressure of 8 atmospheres, for l0 hours. to be completely hardened. and the base and surface materials should be integrated. Thus obtained shaped article was fully dried. and subjected to the physical property tests with the results as given below:

(time required to absorb l cc of water) stantially the same.

The above experiment of Example 5 was repeated except that the water glass component added to the sur- 0 face material was replaced by the water-soluble silicate identified in the table below. The water absorptions of the resulting products were as given also in the same table. while the other physical properties were substantially the same to those obtained in Example 6.

Water Absorption (time required for absorption of 1 cc of water: hrs) Amount Added (part) 0 3 5 I0 10 Type Tetrasodium monosilicate 2Na O.SiO H 0 0.5 l2 l2 to 14 Hexasodium disilicate 3Na O .SiO.,.X H O 0.5 I2 l2 l6 l4 Disodium monosilicate Na O/SiO .X H O 0.5 l I ll l4 I4 EXAMPLE 6 Base material Silex (chemical composition:

Sit): 99.40. Al. .0;, 0.449;. Fe o 0.04: ignition loss: 0.22; 50 Parts Slaked lime ttrit 98K; 50

((aO/SK mol ratio 08) Al=();. (hardening accelerator) l Asbestos S0 Surface material Silex (chemical composition:

SiO: 99.-l-'i AI O; 0.44; Fe- .O;, 0.04; ignition loss: 0.22% 50 Parts Slaked lime (purity: 98% $0 (CaO/SiO n-tol ratio 0.8) ALO (hardening accelerator) Asbestos Surface material Silex (chemicmal composition:

Si 99.4%. AI O; 0.4471. Fe O 0.04%

The base material and surface material of the above compositions were treated similarly as in Example 5, to produce the non-combustible shaped article exhibiting the following physical properties. As the potassiumwater glass in the composition for surface material, that having the SiO /K O mol ratio ranging from 3 to 3.l (A) and that with the same mol ratio ranging from 3.4 to 3.7 (B) were used each in the specified quantities. All the products showed substantially the same properties, regardless the difference in such water glass type and content, except somewhat varying waterabsorptions as shown in the table below:

Physical properties:

The water-absorptions [time (hrs.) required for the article to absorb 1 cc of water] were as follows:

Amount of Potassium-Water Glass l 3 5 I0 Type of Potassium-Water Glass A [0 I3 I4 20 I5 B l0 l3 .I4 20 I5 If no water glass was used, the products water absorption time measured in the same manner was 0.5

15 hour.

EXAMPLES 7 ll Example 5 was repeated except that the compositions of the base and surface materials were varied in each run as in Table 2 below. with the results also given in the same table. The silex and slaked lime employed were identical with those employed in Example 5.

The shaped articles obtained in the above Examples were thoroughly dried and subjected to X-ray diffraction and differential thermal analysis. whereby it was confirmed that the surface and base materials formed gurfaeehhagdnessz 72 fine crystals of the compound of the composition.

enci ar ness: wemheppmor property: Excellem ZrO.SiO- .Cao.H O (Examples 7 and 8) or M- .O.SiO- Peeling: (W, 3 CaO.H O (M standing for Nam Example 9. K in Exam- Table 2 Example Example Example Example Example Composition No. 7 No. 8 No. 9 No. 10 No. l l

Base Material Silex 53 parts 53 parts *1 parts 53 parts 53 parts Slaked lime 47 47 47 47 47 (aO/SiO mol ratio 0.7 0.7 0.7 0.7 0.7 Al Oathardening l parts 1 part 1 part I part I part accelerator) Asbestos 50 parts 50 parts 50 parts 50 parts 50 parts Water I200 I200 I200 I200 l200 Surface material Silex 50 50 50 50 50 Slaked lime 50 50 50 50 50 (aO/SiO mol ratio 0.8 0.8 0.8 0.8 0.8 A1 0 (hardening accelerator) l part I part I part I part I part Zirconium oxide 3 parts Zirconium silicate 3 parts Sodium hydroxide 3 parts Potassium hydroxide 3 parts Lithium hydroxide 3 parts Inorganic pigment cadmium yellow 5 parts red iron oxide 5 arts Water 100 parts 200 parts lOO parts 200 parts 200 parts Test results Surface hardness 63 72 6O 63 72 63 72 63 72 Pencil hardness 9H 9H 9H 9H 9H Weather-proof property Excellent Good Excellent Good Excellent (1,500 hours exposure) Peeling 0% 0'7: 0% 0'7: 0% Abrasion resistance 25 mg 8 mg l7 mg l7 mg 10 mg Water absorption"" l07( l271 I271 I271 Non-combustibility Excellent Excellent Excellent Excellent Excellent Heat resistance Stable u Stable up Stable up Stable up Stable up to 000C to 600C. to 600C. to 600C. to 600C. Boiling test No change No change No change No change No change (4 hours boiling) in surface in surface in surface in surface condition condition condition condition Alkali resistance No change No change ""l'hc water absorption was determined by the percentile weight increase of the sample after 48 hours immersion in water.

ple l0, and Li in Example 1 l to be whereby strongly The sheet-formed base material was fit in a frame of integrated. 9l0 X L820 X 6 mm in size, and onto which the aqueous dispersion of above surface material was coated EXAMPLE 12 with a sprayer, to a thickness of 0.5 to 1.0 mm. On the Base material 5 coated surface a lusterous stainless steel sheet was flatly mounted, and through which the structure was sh' d Silex (chemical composition: under pressure of 200 kg/Cm $029949! M20 044,7 uouo mr Then the structure was subjected to the primary 8 kiglnlition 1051029232) Parts aging in 80 90C. steam for hours. and further to ac tme(pur|ty: n

(caolsioz mol ratio :07) t0 the secondary aging in an autoclme at 180 C. and 8 at- Al ho thardening accelerator) l mospheres. for 10 hours, to be completely hardened.

s estos 50 and the surface and base materials were integrated.

Thus obtained shaped article was thoroughly dried The above composltlon thoroughly kneadedf'vlth and subjected to the physical property tests. with the 1.200 parts of water in a mixer. and thereafter either excellent resuhs as below:

passed through a filtering machine to be removed of the excessive water. or shaped into a sheet with a wet machine, Surface hardness: 63 (\2 Pencil hardness: H Surface material l.000 hours exposure): Excellent 2O Peellng: 0' 2 Non-combustihili [Excellent Boiling test (5 days): No change in Silex (chemical composition: amdilltms SiO 99.4% M 0 0.44% F620;, 0.04%; ater ahsorptlonz 20.5 hours i m 339; 5 p (time required (or ahsorpuon ol l cc of water) Slaketl lime (purity: 98%) 50 Polyvinyl acetate (molecular weight: 20,000) 3 PL 3 15 A1 0. (hardening accelerator) l Example l2 was repeated except that the composi- The above composition was dispersed in 100 parts of tion of surface material was varied in each run as shown water, stirred with a high speed agitator, and filtered to in Table 3 below. The results were as given in the same be removed of the solid component of large particle table. The compositions of silex and slaked lime emsizes exceeding 325 mesh. ployed were identical with those of Example l2.

Table 3 Example Example Example Example Composition No. l3 No. l4 No. l5 No. 16

Surface material 4 Silcx Parts 50 Parts 50 Parts 50 Parts Slaketl lime 50 50 50 50 (aO/SiO mol ratio 0.8 0.8 0.8 0.8 /\l. (hardening accelerator) l part I part Resinous additive llutyl acrylate polymer (molecular weight:20 000) 3 parts Maleic acid-glycol ester polymer (molecular weight:300.000) 3 parts Rubbery styrene! butadiene copolymcr (molecular weight:200.000) 3 parts Inorganic pigment Cadmium yellow 5 parts 5 parts Red iron oxide 5 parts Water 200 parts 200 parts 200 parts 200 parts Test results Surface hardness 63 72 %J 60 63 72 Pencil hardness 9H 9H 6H 9H Weather-proof property No change No change No change No change (L000 hours exposure) Peeling 0'7: 0% 0'7: 0% Non-comhustihility Excellent Excellent Excellent Excellent Boiling test (4 hours) No change No change in surface in surface condition condition Water absorption 5 hours 40 hrs. 30 hrs. 28.5 hrs (time required for ahsorpand I7 tion of 1 cc of water) minutes Heat resistance Stable up Stahle up Stahle u Stahle up to (10(l( lo h00( to (\(l0( to (i00( Alkali resistance No change No change No change No change in surface condition l7 EXAMPLE 17 Base material Silex (chemical composition:

SiO 99.4%, M 0.44%. Fe- O; 0.04% ignition loss: 0.22%) 55 Slaked lime (purity: 98 2) 45 (CaO/SiO- ;mol ratio 0.75) M 0 (reaction promoter) l 50 Asbestos fiber 5 mm) Surface material Silex (chemical com osition:

SiO 9 .493. M 0 044%, Fe O 0.04% ignition loss: 0.2271 50 Parts Slaked lime (purity: 98%) 50 (CaO/Si0 mol ratio 0.8) A1203 (hardening accelerator) l The above composition was stirred with l00 parts of water in a high speed agitator, and filtered to be removed of solid component of large particle sizes exceeding 325 mesh, to form a dispersion.

The sheet-formed base material was fit in a frame of 9l0 X L820 X 6 mm in size, and onto which the above dispersion was coated with a sprayer, to a thickness of 0.5 to l .0 mm. On thus coated surface a lusterous st'ainless steel sheet was flatly mounted, and through which the structure was shaped under a pressure of 200 kg/cm'-.

Thus formed sheet was subjected to the primary aging in 80 90C. steam for hours, and further to the secondary aging in an autoclave at 180C. and 8 atmospheres. for 10 hours. to be hardened and integrated.

On said coated surface further an acrylic paint (Vinyl0se" product of Dainippon Paint K.K.) was applied, and dried to provide a non-combustible shaped article of beautiful appearance.

The results of physical property tests of the above shaped article were as follows:

Surface hardness:

Pencil hardness: 9H

Boiling test 4 hrs.): Excellent Weather-proof property: No change 1 [.500 hrs exposure) Heat resistance: Stable at 200C.

Water-permeability: Low

Surface condition: Smooth EXAMPLE l8 On one of the surfaces of the base material of identical composition with that employed in Example 17. the dispersion of surface material of the identical composition with that of Example l7 was coated. and hardened under the heating of identical conditions as of Example l7. to be integrated. Further onto the surface material.

a water glass type paint (tradename: Potassium-Water Glass", product of Nippon Kagaku Kogyo K.K.) was applied and dried, to provide a non-combustible shaped article with painted surface. The results of physical property tests of this article were as follows:

30 35 9H No change in surface condition Surface hardness: Pencil hardness: Boiling test (4 hrs.): Weather-proof property (2,000 hrs exposure): No change Peeling: 0%, of the paint layer Surface condition: Smooth EXAMPLE 19 The base material and surface material of respectively identical compositions with those employed in Example I? were integrally hardened under identical conditions, and onto the coated surface thereof a styrene/acrylonitrile paint (tradename: V-top," product of Dainippon Paint K.K.) was applied. The structure was then dried to provide a non-combustible shaped article with a paint layer formed on one of its surfaces.

The results of the physical property tests of the shaped article were as follows:

9H No change in surface condition Surface hardness: Pencil hardness: Boiling test: (4 hrs.): Weather-proof property (450 hrs exposure): No change Peeling: 071, of the paint layer Water-permeability: Low Surface condition: Smooth EXAMPLE 20 Surface hardness: 20 Pencil hardness: 9H Weather-proof property I50 hrs exposure): No change Heat resistance: Stable at I50C. Water-permeability: Low Surface condition: Smooth EXAMPLES 2l 27 Example l was repeated except that the compositions specified in Table 4 below were used as the base and surface materials. with the results as shown in the same table. The chemical compositions of silex. slaked lime, and diatomaceous earth were identical with those employed in the foregoing Examples.

Table 4 Example Example Example Example Example Example Example Composition No. 21 No. 22 No. 23 No. 24 No. 25 No. 20 No. 27

Silex 50 parts 50 pans 50 parts 50 pans 50 parts Hy ash 65 parts 65 pans Slakcd lime 35 50 parts 50 pans 50 pans 50 pans 50 parts ('cment 35 parts (an/Sit), mol ratio (1.7 0.7 0.8 0.8 0.8 0.8 0.8 Asbestos 5 mm) 50 pans 50 parts 50 parts 50 pans 20 parts 10 pans 10 parts Polypropylene fiber 2 4 3O 50 50 (3 dc. 10 mm) Rock wool Rock wool Slag wool Water 2500 pans 2500 parts 2500 parts 2500 pans 2500 pans 2500 parts 2500 pans Surface material Silex 100 parts I pans 100 pans I00 pans I00 parts l00 pans Diatomaceous earth 100 arts Slaked lime 150 parts 150 150 parts 150 pans 150 parts 150 pans 150 pans CaO/SiO mol ratio 1.5 1.5 L 1.5 1.5 1.5 1.5 Inorganic pigment (cadmium yellow) l0 pans l0 pans parts 10 pans l0 pans l0 pans l0 parts Water 250 250 250 250 250 250 250 Test results Surface hardness 60 70 40 43 46 45 50 30 40 Pencil hardness 9H 9H 9H 9H 9H 9H 9H Weather-proof property 1,000 hours exposure) Excellent Excellent Excellent Excellent Excellent Excellent Excellent PeelingUZ) 5 l0 0 0 0 6-8 8-10 Water resistance No change No change No change No change No change No change No change Non-combustibility Excellent Excellent Excellent Excellent Excellent Excellent Excellent We claim:

1. A process for the preparation of a noncombustible shaped article which is composed ofa base material. and a surface material integrally bound on at least one surface of said base material, which is applied to said surface as an aqueous dispersion and then hardened under heating as an integral structure, which comprises the steps of:

1. adding to a hydraulic inorganic composition consisting of a water-insoluble inorganic substance composed predominantly of silica and another inorganic substance composed predominantly of calcium oxide. mineral fibers and water. and thoroughly mixing the components.

2. shaping the mixture.

3. separately preparing an aqueous dispersion by dispersing in water a hydraulic inorganic composition consisting of a water-insoluble inorganic substance composed predominantly of silica and another inorganic substance composed predominantly of calcium oxide.

4. applying the aqueous dispersion onto at least one surface of the base material shaped in above step (2),

5. removing the water content from the base material and the surface material thereto under a pressure of 50 to 500 kg/cm*,

6. converting the resulting structure of semihardened shaped article by a primary aging thereof at 60-90C under atmospheric pressure, for 5 to l0 hours,

7. and subjecting the semi-hardened shaped article further to a secondary aging at l50-210C under a steam pressure of 5 to 20 atmospheres, for 5 to 20 hours.

2. A process according to claim 1 wherein the aqueous dispersion in step (3) is prepared by mixing the hydraulic inorganic composition with at least one member selected from group consisting of a water-soluble silicate. a zirconium compound, and an alkali metal hydroxide.

3. A process according to claim 1 wherein the aqueous dispersion in step (3) is prepared by mixing the hydraulic inorganic composition with a resinous additive. an inorganic pigment or mixtures thereof.

4. A process according to claim 2 wherein the aqueous dispersion further contains a resinous additive, an inorganic pigment or mixtures thereof.

5. A process according to claim 1 in which the hydraulic inorganic composition further contains alumina in either the base material or surface composition prepared in step (3) or in both the base material and surface composition.

6. A process according to claim 2 in which the hydraulic inorganic composition further contains alumina in either the base material or surface composition prepared in step (3) or in both the base material and surface composition.

7. A process according to claim 3 in which the hydraulic inorganic composition further contains alumina in either the base material or surface composition prepared in step (3) or in both the base material and surface composition.

8. A process according to claim 4 in which the hydraulic inorganic composition further contains alumina in either the base material or surface composition prepared in step (3) or in both the base material and surface composition.

9. A process according to claim 1 wherein the mol ratio of the calcium oxide to silica in the base material is in the range of 0.5 to 2.0 and wherein the mol ratio of calcium oxide to silica in the hydraulic inorganic composition of step (3) to be applied to the surface of the base material is in the range of 0.8 to 4.0.

10. A process according to claim 2 wherein the mol ratio of the calcium oxide to silica in the base material is in the range of 0.5 to 2.0 and wherein the mol ratio of calcium oxide to silica in the hydraulic inorganic composition of step (3) to be applied to the surface of the base material is in the range of 0.8 to 4.0.

H. The process according to claim 1 wherein in step (1), organic fibers are added to the composition. 

1. A PROCESS FOR THE PREPARATION OF A NON-COMBUSTIBLE SHAPED ARTICLE WHICH IS COMPOSED OF A BASE MATERIAL, AND A SURFACE MATERIAL INTEGRALLY BOUND ON AT LEAST ONE SURFACE OF SAID BASE MATERIAL, WHICH IS APPLIED TO SAID SURFACE AS AN AQUEOUS DISPERSION AND THEN HARDENED UNDER HEATING AS AN INTEGRAL STRUCTURE, WHICH COMPRISES THE STEPS OF:
 1. ADDING TO A HYDRAULIC INORGRANIC COMPOSITION CONSISTING OF A WATER-INSOLUBLE INORGANIC SUBSTANCE COMPOSED PREDOMINANTLY OF SILICA AND ANOTHER INORGANIC SUBSTANCE COMPOSED PREDOMINANTLY OF CALCIUM OXIDE, MINERAL FIBERS AND WATER, AND THOROUGHLY MIXING THE COMPONENTS,
 2. SHAPING A MIXTURE,
 2. A process according to claim 1 wherein the aqueous dispersion in step (3) is prepared by mixing the hydraulic inorganic composition with at least one member selected from group consisting of a water-soluble silicate, a zirconium compound, and an alkali metal hydroxide.
 2. shaping the mixture,
 3. SEPARATELY PREPARING AN AQUEOUS DISPERSION BY DISPERSING IN WATER A HYDRAULIC INORGANIC COMPOSITION CONSISTING OF A WATER-INSOLUBLE INORGANIC SUBSTANCE COMPOSED PREDOMINANTLY OF SILICA AND ANOTHER INORGANIC SUBSTANCE COMPOSED PREDOMINANTLY OF CALCIUM OXIDE.
 3. A process according to claim 1 wherein the aqueous dispersion in step (3) is prepared by mixing the hydraulic inorganic composition with a resinous additive, an inorganic pigment or mixtures thereof.
 3. separately preparing an aqueous dispersion by dispersing in water a hydraulic inorganic composition consisting of a water-insoluble inorganic substance composed predominantly of silica and another inorganic substance composed predominantly of calcium oxide.
 4. A process according to claim 2 wherein the aqueous dispersion further contains a resinous additive, an inorganic pigment or mixtures thereof.
 4. APPLYING THE AQUEOUS DISPERSION ONTO AT LEAST ONE SURFACE OF THE BASE MATERIAL SHAPED IN ABOVE STEP (2),
 4. applying the aqueous dispersion onto at least one surface of the base material shaped in above step (2),
 5. removing the water content from the base material and the surface material thereto under a pressure of 50 to 500 kg/cm2,
 5. A process according to claim 1 in which the hydraulic inorganic composition further contains alumina in either the base material or surface composition prepared in step (3) or in both the base material and surface composition.
 5. REMOVING THE WATER CONTENT FROM THE BASE MATERIAL AND THE SURFACE MATERIAL THERETO UNDER A PRESSURE OF 50 TO 500 KG/CM2,
 6. converting the resulting structure of semi-hardened shaped article by a primary aging thereof at 60*-90*C under atmospheric pressure, for 5 to 10 hours,
 6. A process according to claim 2 in which the hydraulic inorganic composition further contains alumina in either the base material or surface composition prepared in step (3) or in both the base material and surface composition.
 6. CONVERTING THE RESULTING STRUCTURE OF SEMI-HARDENED SHAPED ARTICLE BY A PRIMARY AGING THEREOF AT 60*-90*C UNDER ATMOSPHERIC PRESSURE, FOR 5 TO 10 HOURS,
 7. A process according to claim 3 in which the hydraulic inorganic composition further contains alumina in either the base material or surface composition prepared in step (3) or in both the base material and surface composition.
 7. and subjecting the semi-hardened shaped article further to a secondary aging at 150*-210*C under a steam pressure of 5 to 20 atmospheres, for 5 to 20 hours.
 7. AND SUBJECTING THE SEMI-HARDENED SHAPED ARTICLE FURTHER TO A SECONDARY AGING AT 150* - 210*C UNDER A STEAM PRESSURE OF 5 TO 20 ATMOSPHERES, FOR 5 TO 20 HOURS.
 8. A process according to claim 4 in which the hydraulic inorganic composition further contains alumina in either the base material or surface composition prepared in step (3) or in both the base material and surface composition.
 9. A process according to claim 1 wherein the mol ratio of the calcium oxide to silica in the base material is in the range of 0.5 to 2.0 and wherein the mol ratio of calcium oxide to silica in the hydraulic inorganic composition of step (3) to be applied to the surface of the base material is in the range of 0.8 to 4.0.
 10. A process according to claim 2 wherein the mol ratio of the calcium oxide to silica in the base material is in the range of 0.5 to 2.0 and wherein the mol ratio of calcium oxide to silica in the hydraulic inorganic composition of step (3) to be applied to the surface of the base material is in the range of 0.8 to 4.0.
 11. The process according to claim 1 wherein in step (1), organic fibers are added to the composition. 